Download Worcester R40HE Technical data

Installation and Servicing Instructions
R29 & R40 HE conventional
Wall mounted condensing boiler for central heating
6 720 610 577-01.10
6 720 611 445 GB (03.11) TD
ZB 7-28 R29 HE GC-Number: 47 311 60
ZB 11-40 R40 HE GC-Number: 47 311 61
Contents
Contents
Safety precautions
3
Symbols
3
1
1.1
1.2
1.3
1.4
1.5
1.6
1.7
1.8
1.9
Details of the appliance
EC Declaration of Conformity
Standard package
Description of appliance
Accessories
Casing dimensions
Layout of appliance
Function
Electrical wiring diagram
Technical data
4
4
4
4
5
5
6
7
8
9
2
Installation regulations
11
3
3.1
3.2
3.3
3.4
3.5
3.6
3.7
3.8
3.8.1
3.8.2
3.8.3
Installation
Important remarks
System
Siting the appliance
Wall mounting frame assembly
Pre-piping the system
Fitting the appliance
Checking the connections
Flue Systems
Siting the Flue Terminal
Installation of the flue
Flue duct preparation and assembly
11
11
11
13
14
14
15
16
16
17
18
19
4
4.1
4.2
Electrical connections
Connecting the appliance
Wiring to your system
21
21
22
5
5.1
5.2
5.3
5.4
5.5
5.6
Commissioning
Commissioning
Switching the appliance on/off
Switching on the Boiler
System controls
Frost protection
Fault Condition
23
23
24
24
24
24
25
6
6.1
6.1.1
6.2
6.2.1
6.2.2
Individual settings
Mechanical settings
Setting the boiler flow temperature
Settings on the Bosch Heatronic
Operating the Bosch Heatronic
Setting the anti-cycle time
(Service Function 2.4)
6.2.3 Setting the maximum boiler flow temperature
(Service Function 2.5)
2
6.2.4 Setting the switching difference
(Service Function 2.6)
6.2.5 Setting the heating output
(Service Function 5.0)
6.3 Setting the gas/air ratio
27
27
28
7
Converting the appliance to different gas
types
29
7.1 Setting the gas/air ratio
29
7.2 Testing combustion air/flue gas at set heat output
31
7.2.1 Testing the O2 or CO2 level in the combustion
air
31
7.2.2 Testing CO and CO2
31
8
8.1
8.2
8.3
8.3.1
8.3.2
8.3.3
8.3.4
8.3.5
8.3.6
8.3.7
8.3.8
Maintenance
Pre-Service Check List
Description of servicing operations
Replacement of Parts
PCB control board and transformer
Fan Assembly
Sensors
Gas Valve
Electrode assembly
Pressure Relief Valve
Burner
Primary Heat Exchanger
32
33
34
37
37
38
38
38
39
39
39
39
9
9.1
9.2
9.3
9.4
9.5
9.5.1
Appendix
Fault Codes
Short parts list
Heating/hot water output settings (N.G)
Heating/hot water output settings (L.P.G)
Operational Flow diagrams
Central heating function
40
40
41
41
41
42
42
26
26
26
26
26
27
27
6 720 611 445 GB (03.11)
Safety precautions
Safety precautions
If you smell gas
B Turn off gas service cock at the meter.
B Open windows and doors.
B Do not operate any electrical switches.
B Extinguish any naked flames.
B Telephone your gas company.
If you smell fumes from the appliance
B Switch off appliance (see page 24).
B Open windows and doors.
Unpacking
IMPORTANT HANDLING INSTRUCTIONS
B Two people should transfer the packaged appliance
from the van to the point of installation
B Open the top of the carton, remove and place the
component tray and both side bars of the wall mounting frame to one side
B Lie the packaged appliance on its back. (The back
has “TRUCK HERE” printed on the carton)
B One person firmly holds the packaging while the
other straddles the boiler and slides it from the packaging
Fitting and modifications
B Fitting of the appliance or any controls to the appliance may only be carried out by a competent engineer in accordance with the Gas Safety (Installation
and Use) Regulations 1998.
B Flue systems must not be modified in any ways other
than as described in the fitting instructions.
B This appliance is for use with fully pumped, sealed and
open vent systems only.
B Two persons are then required to lift one end and
stand the appliance upright with the flue at the top
Maintenance
B The user is recommended: to have the system
regularly serviced in order to ensure that it functions
reliably and safely.
B Use only original spare parts!
Check the contents against the packing list.
Additional requirements for roof space installation
B Two people should use two step ladders and share
lifting the unpacked boiler up to the loft hatch
B Where the boiler enters the loft space, tilt and slide
the boiler on its back to the point of installation
Symbols
Safety instructions in this document
are identified by a warning-triangle symbol and are printed on a grey background.
Combustible materials
B Do not store or use any combustible materials
(paper, thinners, paints etc.) in the vicinity of the
appliance.
Health and safety
B This appliance contains no asbestos products.
B There is no potential hazard due to the appliance
being electrically unsafe.
B There are no substances used in the construction
that are a potential hazard in relation to the COSHH
Regulations (Control of Substances Hazardous to
Health Regulations 1988).
i
Notes containing important information
are identified by the symbol shown on the
left. They are bordered by horizontal lines
above and below the text.
Combustion air/Ambient atmosphere
B The combustion air/ambient atmosphere should be
kept free of chemically aggressive substances (e.g.
halogenated hydrocarbons which contain chlorine or
fluorine compounds). This will prevent corrosion.
Instructions to the customer
B Explain to the customer how the appliance works and
how to operate it.
B Advise the user that he/she must not make any modifications to the appliance or carry out any repairs on it.
B These instructions are to be left with the user or at
the Gas meter.
B Important: These instructions apply in the UK only.
6 720 611 445 GB (03.11)
3
Details of the appliance
1
Details of the appliance
1.3
Description of appliance
• Wall-mounted appliance
1.1
EC Declaration of Conformity
• Natural gas models are low-emission appliances
This appliance is in accordance with the applicable
requirements of the Gas Appliance Directive, Boiler Efficiency Directive, Electromagnetic Compatibility Directive and the Low Voltage Directive.
• Multi function display
PIN
CE-0085 BL 0507
Category
UK
II2H 3P
• Full safety systems incorporating Bosch Heatronic
with flame ionisation monitoring, solenoid valves and
temperature sensors
Appliance Type
C13, C33
• Bosch Heatronic control system
• Automatic ignition
• Modulating control
• Concentric flue/air duct with testing point for
CO2/CO
• Regulated speed fan
Table 1
• Pre-mix burner
1.2
Standard package
• Gas condensing boiler for central heating
• Wall mounting frame
• Fixings (screws etc.)
• Set of documentation for appliance
• Pre-plumbing manifold
• Condensate drain pipe.
4
• Temperature control for boiler flow
• Safety temperature limiter in 24 V electrical circuit
• Flue gas temperature limiter (105 °C)
• Condensate Trap
• Connecting possibility for 3 port or 2 x 2 port motorised valve systems
• Suitable for fully pumped sealed and open vent systems.
6 720 611 445 GB (03.11)
Details of the appliance
1.4
Accessories
diameter) for flue lengths up to 13m (R 29 HE ) or
10m (R 40 HE) and vertical flue systems for flue
lengths up to 13.7 m (R 29 HE) or 10.7m (R 40 HE).
Fitting instructions are sent with these kits.
• Standard horizontal flue kit at 100 mm outside
diameter for flues up to 4 m in length (3.5m for the R
40 HE).
• Flue duct kits for horizontal (125 mm outside
1.5
Casing dimensions
min
min
10*
10*
Z
600*
X
Y
850
850
120
101
13
103
30
200
35
360
395
*
200
440
6 720 610 601- 01.4O
Fig. 1
13
101
103
X
Manifold assembly
Outer case
Facia cover
Standard Concentric Horizontal Flue System: min. 160 mm
Alternative Concentric Flue System: min. 220 mm
Y
Standard Concentric Horizontal Flue System: 40 mm
Alternative Concentric Flue System: 70 mm
Z
Standard Concentric Horizontal Flue System: 105 mm
Alternative Concentric Flue System: 130 mm
*
For servicing the appliance
Note: Horizontal flue only: dimension X may need to increase due
to the incline of the flue.
6 720 611 445 GB (03.11)
5
Details of the appliance
1.6
Layout of appliance
120
221.1
221.2
226
102
27
32.1
29
36
271
6
415
43
9
63
416
358
64
423
4.4
7
15
361
295
4
417
Fig. 2
4
4.4
6
7
9
15
27
29
32.1
36
43
63
64
102
120
6
Heatronic control
Y-S module
Heat exchanger safety temperature limiter
Testing point for gas supply pressure
Flue gas temperature limiter
Relief valve
Automatic air vent
Air gas Mixer unit
Electrode assembly
Temperature sensor in boiler flow
Flow pipe
Adjustable gas flow restrictor
Adjusting screw for min. gas flow volume
Inspection window
Fixing points
221.1
221.2
226
295
271
358
361
415
416
417
423
Flue duct
Combustion air intake
Fan assembly
Appliance type sticker
Flue duct
Condensate trap
Drain valve
Cover plate for cleaning access
Condensate collector
Clip for fixing outer case
Siphon
6 720 611 445 GB (03.11)
Details of the appliance
1.7
Function
4.4
361
Fig. 3
4
4.4
6
7
9
13
15
27
29
29.1
30
32
33
35
36
43
45
47
52
52.1
55
56
57
61
63
64
69
221
226
229
Bosch Heatronic control
Y-S module
Temperature limiter, heat exchanger
Testing point for gas supply pressure
Flue gas temperature limiter
Manifold
Safety valve
Automatic air vent
Mixer unit
Bi-metallic thermostat for combustion air compensation
Burner
Flame sensing electrode
Igniter electrode
Heat exchanger with cooled combustion chamber
Temperature sensor in boiler flow
Boiler flow
Gas inlet
Return
Solenoid valve 1
Solenoid valve 2
Filter
Gas valve CE 427
Main valve disc
Reset button
Adjustable gas flow restrictor
Adjusting screw for min. gas inlet flow volume
Control valve
Flue duct
Fan
Inner casing
6 720 611 445 GB (03.11)
317
358
361
423
443
Display
Condensate trap
Drain valve
Siphon
Diaphragm
7
Details of the appliance
1.8
Electrical wiring diagram
o - orange
bl - black
r - red
33
365
364
61
366
363
367
ECO
4.1
25 V
153
230V/AC
230 V
136
310
135
312
328
302
313
151
124 789
L N Ns Ls LR
161
300
9
6
M
r
r
mains supply
o
226
52
4.4
52.1
56
o
bl
bl
bl
bl
36
32
6 720 610 601-03.2O
Fig. 4
4.1
4.4
6
9
32
33
36
52
52.1
56
61
135
136
151
153
161
226
300
302
310
8
Ignition transformer
Y-S module
Temperature limiter, heat exchanger
Flue gas temperature limiter
Flame sensing electrode
Ignition electrode
Temperature sensor in boiler flow
Solenoid valve 1
Solenoid valve 2
Gas valve CE 427
Reset button
Master switch
Temperature control for boiler flow
Fuse, slow 2.5 A, AC 230 V
Transformer
Link
Fan
Code plug
Earth connection
Function control (Service only)
312
313
328
363
364
365
366
367
Fuse, slow T 1,6 A
Fuse, slow T 0,5 A
Terminal block for AC 230 V Mains supply
Indicator lamp for burner
Indicator lamp for power supply
“Chimney sweep” button
Service button
No function
6 720 611 445 GB (03.11)
Details of the appliance
1.9
Technical data
Units
R29 HE
Natural gas
R29 HE
Propane
R40 HE
Natural gas
R40 HE
Propane
kW
kW
kw
29.3
29.0
27.4
29.3
29.0
27.4
41.4
41.4
39.1
41.4
41.4
39.1
Max. rated heat input net
kW
27.7
27.7
40
40
Min. rated heat output net 40/30°C
Min. rated heat output net 50/30°C
Min. rated heat output net 80/60°C
kW
kW
kW
8.4
8.3
7.4
11.6
11.4
10.5
12.9
12.8
11.4
16.2
16.1
14.3
Min. rated heat input net
kW
7.6
10.8
11.8
14.8
4.2
-
Max. rated heat output net 40/30°C central heating
Max. rated heat output net 50/30°C central heating
Max. rated heat output net 80/60°C central heating
Maximum gas flow rate – After 10 minutes from lighting
Natural gas G20 (CVnet 34.02 MJ/m3)
m3/h
2.9
-
MJ/m3)
kg/h
-
2.1
Natural gas G20 (CVnet 34.02 MJ/m3)
mbar
20
-
20
-
LPG (CVnet 88 MJ/m3)
mbar
-
37
-
37
Flue gas temp. 80/60°C, rated/min. load
°C
67/55
67/55
87/58
87/58
Flue gas temp. 40/30°C, rated/min. load
°C
43/32
43/32
65/43
65/43
Residual delivery pressure
(inc. pressure drop in air intake duct)
Pa
80
80
100
100
CO2 level at max. rated heat output
CO2 level at min. rated heat output
%
%
9.2
8.8
10.8
10.5
9.2
9.2
10.8
10.8
5
5
5
5
A
A
A
A
LPG (CVnet 88
3.2
Gas supply pressure
Flue
NOx-class
SEDBUK figure
Band
Condensate
Max. condensation rate (tR = 30°C)
l/h
2.3
2.3
3.5
3.5
4.8
4.8
4.8
4.8
AC ... V
230
230
230
230
Frequency
Hz
50
50
50
50
Max. power consumption
W
43
43
113
113
dB(A)
36
36
42
42
IP
X4D
X4D
X4D
X4D
Max. boiler flow temperature
°C
nom. 90
nom. 90
nom.90
nom.90
Max. permissible operating pressure (boiler)
bar
3
3
3
3
Permissible ambient temperatures
°C
0 - 50
0 - 50
0 - 50
0 - 50
Nominal capacity of appliance
l
3.75
3.75
3.75
3.75
Weight (excluding packaging)
kg
43
43
43
43
pH-value, approx.
General Data
Electrical power supply voltage
Noise output level
Appliance protection rating with blanking plate fitted
Table 2
6 720 611 445 GB (03.11)
9
Details of the appliance
Gas supply
Condensate analysis, mg/l
Ammonium
1.2
≤ 0.01
Lead
Nickel
0.15
Mercury
≤ 0.0001
Cadmium
≤ 0.001
Sulphate
Chromium
≤ 0.005
Zinc
≤ 0.015
Tin
≤ 0.01
Halogenated
hydrocarbons
≤ 0.002
Hydrocarbons
0.015
Vanadium
Copper
0.028
pH-value
1
Total length of gas supply pipe
(metres)
3
6
Pipe diameter
(mm)
9
Gas discharge rate (m3/h)
8.7
5.8
4.6
22
18.0
12.0
9.4
28
≤ 0.001
4.8
Table 8
Table 3
Flue system
HORIZONTAL 100 mm – Standard FLUE SYSTEM
Overall Diameter of Duct
mm
100
Flue Terminal / Duct
Assembly Length
mm
600
Extension Duct Length
mm
1000
Max.
R29 4m
R40 3.5m
(including
turret)
Table 4
VERTICAL 100mm FLUE SYSTEM
Overall Diameter of Duct
mm
100
Flue Terminal / Duct
Assembly Length
mm
1140
Max. (Excl.
terminal)
R29 5m
R40 4m
Table 5
HORIZONTAL 125 mm FLUE SYSTEM
Overall Diameter of Duct
mm
125
Flue Terminal / Duct
Assembly Length
mm
1030
Max.
R29 13m
R40 10m
(including
turret)
Table 6
VERTICAL 125 mm FLUE SYSTEM
Overall Diameter of Duct
mm
125
Flue Terminal / Duct
Assembly Length
mm
1365
Max. (EXCL)
terminal)
R29 13.7m
R40 10.7m
Table 7
Elbow - 90 ° Equivalent length 2 m
Bend - 45 ° Equivalent length 1m
10
6 720 611 445 GB (03.11)
Installation regulations
2
Installation regulations
Gas Safety (Installation & Use) Regulations 1998: All
gas appliances must be installed by a competent person. Failure to install correctly could lead to prosecution.
The manufacturers notes must not be taken, in any way,
as overriding statutory obligations.
The appliance must be installed in accordance with the
current IEE Wiring Regulations, local Building Regulations, Building Standards (Scotland) (Consolidation),
bye-laws of the local Water Company, Health and
Safety Document 635 (Electricity at Work Regulations
1989) and any other local requirements.
Product Liability regulations indicate that, in certain circumstances, the installer can be held responsible, not
only for mistakes on his part but also for damage resulting from the use of faulty materials. We advise the
installer to avoid any risk by using only quality approved
branded fittings.
The relevant British Standards should be followed i.e.
• BS 6798: Specification for the installation of gas
fired hot water boilers of rated input not exceeding
60kW
• BS 5449: Central Heating for Domestic Premises
• BS 5546: Installation of gas hot water supplies for
domestic purposes
• BS 5440:1: Flues and ventilation for gas appliances
of rated input not exceeding 70 kW (net): Flues
• BS 5440:2: Flues and ventilation for gas appliances
of rated input not exceeding 70 kW (net): Air
Supply
• BS 6891: Installation of low pressure gas pipe work
installations up to 28 mm (R1).
• BS 7074:1: Code of practice for domestic heating
and hot water supply
• BS 7671: Requirements for Electrical Installation.
These instructions must be followed.
3
Installation
B Always turn off the gas cock before carrying out any work on components
which carry gas.
i
3.1
Fixing of the appliance, gas and flue connections, commissioning of the system
and electrical connections may only be
carried out by competent persons authorised by CORGI.
Important remarks
B Appliance should only be installed in fully pumped
sealed and open vent central heating systems.
B To avoid gas formation in the system, galvanised radiators or pipes must not be used.
B Do not fit a thermostatic radiator valve on the radiator
in the primary room where a room thermostat is used.
B Add a suitable anti-freeze fluid compatible with aluminium to the water in the central heating system.
Suitable products are available from Betz-Dearborn
Tel: 0151-4209563 and Fernox Tel: 01799550811.
B In our experience, the addition of sealing agents to
the water in the central heating system can cause
problems (deposits in the heat exchanger). For that
reason we advise against their use.
3.2
System
The system must comply with the requirements of BS
6798 and BS 5449.
General
The appliance is only suitable for connection to indirect
fully pumped sealed and open vented systems. The minimum static head is 1m and the maximum is 30m.
The controls must be wired to ensure that the boiler
does not cycle when the electronically controlled zone
valves are closed.
Note 1: An automatic bypass is required if the controls
i.e. 2-port valves, can result in the closure of the CH and
DHW circuits when the boiler is hot. If mechanically
operated thermostatic control valves are fitted on all
radiators an automatic bypass is required, located at
least 2m from the boiler.
Note 2: A bypass is not usually required for systems
using a 3-way diverter valve (with one valve is open to
flow at all times) unless TRV’s are used throughout the
system. Refer to the current Building Regulations or the
Good Practice Guide 302 which lists all the above
requirements.
Plastic pipes must not be directly connected to the
appliance. A copper to plastic transition piece should
be positioned a minimum of 600mm from the appliance.
6 720 611 445 GB (03.11)
11
Installation
Some plastics are permeable to oxygen and must be
avoided, a pipe with a polymer barrier should be used.
tee. The pH value of the system water must be less than
8 or the appliance guarantee will be invalidated.
Sealed System
Suitable products are available from Betz-Dearborn Tel:
0151-4209563 and Fernox Tel: 01799-550811.
A sealed system must include an expansion vessel,
pressure gauge and pressure relief valve set to operate
at 3 bar - these are available as proprietary kits. The
expansion vessel and fittings must be connected at the
neutral point of the system on the entry to the pump.
Suitable pump and diverter valves are also required.
Refer to Fig. 5 & Fig. 6. The sealed system must be filled
through a WRAS approved filling kit. Refer to Fig. 7.
The appliance must not be operated without the system
being full of water and correctly pressurised.
All connections in the system must be able to withstand
a pressure up to 3 bar. The system and appliance must
be properly vented. Repeated venting loses water from
the system and usually indicates a leak. A drain cock to
BS 2879 must be fitted to the lowest point on the system.
No galvanised radiators or pipes must be used.
If any system water treatment is required then only products suitable for use with Aluminium shall be used i.e
Fernox- Copal or Super concentrate or Sentinal X100,
in accordance with the manufacturers instructions. The
use of any other substances will invalidate the guaran-
IMPORTANT: Check that no dirt is left in the water
pipe work as this could damage the appliance. Thoroughly flush the heating system and the mains water
supply before fitting the appliance to the wall in accordance with the recommendations of BS7593:1992.
Domestic Hot Water
The appliance is NOT suitable for direct water
supply.
Do not connect to a direct cylinder.
The appliance can be connected to any indirect cylinder
i.e. unvented or thermal store to realise the benefits from
a “dry loft”. For more information contact Worcester
Heat Systems Helpline 08705 266241.
Note: Indirect coil type cylinders with an immersion calorifier suitable for a pressure of 0.35 bar above the setting of the pressure relief valve may be used. Single
feed indirect cylinders are not suitable for sealed
systems. Any connection to the mains water supply
must conform to the relevant Buildings and Water Regulations and be approved by the local water company.
FEED & VENT
CISTERN
S.H.
HEATING
VENT
Minimum
diameter
22mm.
PRIMARY
COLD FEED
Minimum
diameter
15mm.
S.H. MINIMUM STATIC HEAD 1.0m MEASURED
FROM THE HIGHEST POINT IN THE HEATING
SYSTEM (TOP SURFACE OF THE APPLIANCE
OR HIGHEST POINT IN THE HEATING
SYSTEM) TO THE WATER LEVEL IN THE FEED
AND EXPANSION TANK.
DOMESTIC
HOT WATER
CYLINDER
S.H.
RADIATOR
RADIATOR
RADIATOR
RADIATOR
150mm
max.
DIVERTER
VALVE
PUMP
BOILER
TYPICAL OPEN VENTED SYSTEM
DRAIN
COCK
Fig. 5
12
6 720 611 445 GB (03.11)
Installation
AUTOMATIC
AIR VENT
DOMESTIC
HOT WATER
CYLINDER
RADIATOR
RADIATOR
RADIATOR
RADIATOR
DIVERTER
VALVE
SAFETY
VALVE
PRESSURE
GAUGE
PUMP
EXPANSION
VESSEL
BOILER
TO SYSTEM
FILLING
DEVICE
DRAIN
COCK
TYPICAL FULLY PUMPED SEALED SYSTEM
Fig. 6
Fig. 7
3.3
Siting the appliance
and fitted furniture. The specified clearances must be
maintained.
Regulations concerning the Installation Site
B Relevant national regulations must be complied with
section 3.8.1.
B Consult the installation instructions for details of minimum clearances required.
Combustion air
Cupboard/Compartment
The appliance can be installed in a cupboard/compartment need for airing clothes providing that the requirements of BS 6798 and BS 5440:2 are followed. The
low casing losses from the appliance eliminate the need
for ventilation openings in the compartment.
In order to prevent corrosion, the combustion air must
not contain any corrosive substances.
Substances classed as corrosion-promoting include
halogenated hydrocarbons which contain chlorine and
fluorine compounds and are contained in some solvents, paints, adhesives, aerosol propellants and household cleaners, for example.
Surface temperature
The max. surface temperature of the casing and the flue
is less than 85 °C.
This means that, no special safety precautions are
required with regard to flammable building materials
6 720 611 445 GB (03.11)
13
Installation
3.4
Wall mounting frame assembly
B Take the wall mounting frame out of the package and
screw together with 6 screws as shown in fig. 8. Use
the inner lugs on the top and bottom horizontal sections.
B Screw the pre-plumbing manifold with two screws to
the wall mounting frame.
6 720 610 576-11.1O
Fig. 10
6 720 610 576-04.1O
3.5
Pre-piping the system
Fig. 8
200
B Hold the wall-mounting frame against the wall ensuring that it is vertical.
B Mark the holes for the wall mounting frame onto the
wall, drill and plug the holes and screw the wall
mounting frame to the wall with the screws provided.
B Mark the position of the flue duct hole if a rear flue is
to be used. Refer to fig. 1 and 17.
171
112
172
43
47
35
50
120-130
260
6 720 610 576-06.1O
Fig. 11 Manifold
43
47
112
171
172
6 720 610 576-05.1O
Fig. 9
14
Boiler flow
Boiler return
Gas cock
Not used
Not used
B Remove valves 171 and 172 from manifold, see Fig.
11.
B A drain tap should be fitted at the lowest point of the
central heating system.
6 720 611 445 GB (03.11)
Installation
Condensate Termination and Route
The appliance has a built-in syphonic condensate trap
eliminating the need for external traps. Connect to the
22mm plastic drain pipe and extend the pipe run away
from the control panel and appliance witha constant fall
of 2.5° or 25mm in every metre. See Fig. 13.
The condensate pipe can terminate into any of four
areas:
If there is no alternative and the condensate pipe has to
be externally run, the following should be considered:
• The pipe run should take the shortest practical route.
• The pipework should be insulated with weather
resistant insulation.
• The pipe should terminate as close as possible to the
ground or drain, whilst still allowing the condensate
to safely disperse. This would prevent wind blowing
up the pipe.
Boiler
Boiler
Ø 22 min.
Sink
Siphon
No length
restriction
Siphon
Ø 22 min.
75 min. trap
Open end of pipe
direct into gully,
below ground but
above water level.
Use waterproof pipe work
insulation in very exposed
positions
The gradient of the discharge pipe
should be 2.5¡ (40 mm/m) minimum
Open end of pipe direct
into gully, below ground
but above water level
An internal waste system
3.6
The gradient of the discharge pipe should be
2.5¡ (40 mm/m) minimum
Benchmark: For optimum performance
after installation, this boiler and its associated central heating system must be
flushed in accordance with the guidelines given in BS5793:1992 “Treatment
of water in domestic hot water central
heating systems”.
Boiler
Internal soil
and vent stack
Ø 22 min.
No length
restriction
Sink
Siphon
The gradient of the discharge pipe
should be 2.5¡ (40 mm/m) minimum
75 min. trap
450 min.
Ø 22 min.
75 min. trap
Fitting the appliance
An external waste system
Boiler
No length
restriction
• The pipework should be installed with the minimum
of horizontal runs and with a downward slope of at
least 2.5 °.
Invert
The rainwater system
Open end of pipe
direct into gully,
below ground but
above water level
The gradient of the discharge pipe
should be 2.5¡ (40 mm/m) minimum
An external purpose made soakaway
6 720 610 596 -03.2TD
Fig. 12
Whilst all of the above methods are acceptable it is
always the best practice to terminate the condense pipe
via an internal waste system.This will eliminate the need
for any external condensate pipe runs which can be susceptible to freezing in extreme weather.
Removing the outer case
i
The outer case is secured against unauthorised removal by two screws (electrical
safety).Always secure the outer case with
those screws again after refitting.
B Remove retaining screws (1.).
B Slide the outer case upwards and then forwards to
remove (2.).
B Remove the plastic caps from the boiler connections.
2
1
Fig. 13 Recommended route of the condensate drain
External condensate pipework
The syphonic condensate trap collects condensate into
a trap which releases it in 100 ml quantities. This helps
to prevent the discharge from freezing.
6 720 611 445 GB (03.11)
Fig. 14
15
Installation
Fixing the appliance
3.7
B Fit the washers onto the gas and water connections.
Water connections
B Lift the boiler onto the wall-mounting frame. The lugs
pass through the rectangular holes in the boiler back
panel.
B Take care not to disturb the washers on the connections.
Connecting the flue assembly
B Fit flue duct connector onto appliance flue spigot.
B Secure with the screws supplied.
B Turn on the service valves for boiler flow and return.
B Check all seals and unions for leaks.
Open vent systems: It is not necessary to connect a
drain pipe to the pressure relief valve outlet as it is not
operational and should be blanked off.
B Check that the seal is in place before tightening the
connection.
B Turn off gas cock to protect gas valve against damage from excessive pressure.
Flue seal
Appliance
Flue Socket
B Check that the O-rings or seals are in place before
tightening the connection.
Gas supply pipe
Flue Turret
Retaining
Screw
Checking the connections
B Check gas supply pipe.
B Release the pressure on the gas supply pipe.
Flue Turret to
Boiler Sealing
Gasket
6 720 610 599 - 01.TD
Fig. 15
B For remaining installation of flue assembly, refer to
the relevant installation instructions.
3.8
Flue Systems
The only flue systems that may be used are those supplied by Worcester Heat Systems.
The flue system must be installed in accordance with
the requirements of BS 5440:1.
Standard 100 mm flue system
The standard concentric flue system provides for a horizontal length of up to 4m (R29) and 3.5m (R40). Full
instructions for fitting this flue are in Subsection 3.8.2
“Installation of the flue”.
Alternative 125 mm diameter flue systems
Installation instructions for the alternative flue
systems are sent with the appropriate flue kit.
Systems are available to give a maximum horizontal
length of 13m (R29) and 10m (R40).
A vertical flue system up to a height of 13.7m (10.7m
R40) is available.
45° and 90° flue bends can be used with a corresponding reduction in flue length of 2 m for each 90° bend and
1 m for each 45° bend used.
IMPORTANT: Any horizontal flue system fitted to a
condensing boiler must incline from the appliance at an
angle of 3° (30 mm per metre length) to prevent condensate dripping from the flue terminal.
Note, the standard 100mm horizontal flue requires only
a 0.5° incline from the boiler as the inner exhaust pipe is
inclined at 2.5° inside the outer pipe.
This means that the clearance above the appliance must be increased to match the duct length.
Refer to fig. 1 on page 5.
16
6 720 611 445 GB (03.11)
Installation
3.8.1
lighting, activated by passive infra-red sensing heads.
If the terminal is less than 2 m above a surface to which
people have access then a guard must be fitted. The
guard must be evenly spaced about the terminal with a
space of 50 mm in each direction and fixed with plated
screws.
A guard Type K6 for the standard horizontal flue, can be
obtained from Tower Flue Components, Vale Rise, Tonbridge TN9 1TB.
Siting the Flue Terminal
The flue must be installed in accordance with
BS 5440:1 and the Building Regulations. Flue terminals
in carports and under balconies are to be avoided.
The terminal must be positioned so that it does not
cause an obstruction nor the combustion products a
nuisance. See fig. 16 and table 9.
The terminal will, at times, give out a plume of water
vapour and consideration must be given to this when
choosing a terminal position. Keep clear of security
P
Q
boundary
Q
I
D,E
Q
B
H
C
F
J
N
A
L
G
M
H
I
H
K
Fig. 16
Minimum dimensions of flue terminal positions (all types) (see fig. 16)
Dimension
Terminal Position (kW input expressed in net)
A1)
Directly below an opening, air brick, opening windows, etc.
1)
Balanced flues room sealed: Fanned draught
300 mm
Above an opening, air brick, opening window, etc.
300 mm
C1)
Horizontally to an opening, air brick, opening window, etc.
300 mm
D
Below gutters, soil pipes or drain pipes
E
Below eaves
200 mm
F
Below balconies or car port roof (lowest point)
Not recommended
G
From a vertical drain pipe or soil pipe
H
From an internal or external corner or to a boundary alongside the terminal
I
Above ground roof or balcony level
J
From a surface or boundary facing the terminal
1200 mm
B
75 mm
75 mm
300 mm
300 mm
K
From a terminal facing the terminal
2000 mm
L
From an opening in the car port (e. g. door, window) into the dwelling
Not recommended
M
Vertically from a terminal on the same wall
1500mm
N
Horizontally from a terminal on the same wall
300 mm
P
From a vertical structure on the roof
500 mm
Q
Above intersection with roof
300 mm
Table 9
1)
In addition, the terminal should not be nearer than 150 mm (fanned draught) to an opening in the building fabric formed for the purpose of accommodating a built-in element such as a window frame.
6 720 611 445 GB (03.11)
17
Installation
3.8.2
Installation of the flue
The standard 100 mm diameter horizontal flue system is
suitable for lengths up to 4m (R29) & 3.5m (R40).
Flues up to 650 mm do not require an extension duct
assembly.
Flues between 600 mm and 4000 mm (3500 mm R40)
require extension duct assemblies.
NOTE: Flue lengths between 650 mm and 730 mm
cannot be accommodated. Refer to fig. 18, 19, 20.
Flue
Turret
Standard 100mm system comprise:
• Flue turret
Maximum 650mm
Outer
Wall
Minimum 100mm
• Flue turret clamp
• Terminal assembly
Clamp
• Wall sealing gasket and cover plate.
Terminal
Assembly
6 720 610 599 - 01.TD
Refer to fig. 21.
Instructions for fitting other flue systems are packed
with the relevant flue kit.
Check that the position chosen for the appliance is satisfactory. Refer to fig. 17.
Centre line of
flue/air duct
H
Fig. 18 Standard Flue
m
120m
3°
Top of wall
mounting
frame (not
boiler)
Appliance
Drilling
point for
flue duct
opening
H = 40mm for the Standard 100mm Horizontal Flue
H = 70mm for the Optional 125mm Horizontal Flue
6 720 610 602-08.3O
Centre
line of
flue
opening
and
appliance
(30mm/metre)
Standard 100mm
horizontal flue 0.5°
(5mm/metre)
Fig. 17 Marking the position of the side flue opening.
Note: ensure there is adequate access to the
air/flue sampling points in the flue turret.
18
6 720 611 445 GB (03.11)
Installation
Maximum 1600mm
Outer
Wall
Flue
Turret
Extension
Duct
Clamp
Terminal
Assembly
6 720 610 599 - 00.TD
Fig. 19 Flue with one extension
Outer
Wall
Flue
Turret
Clamp
Extension
Duct
Clamp
Extension
Duct
Clamp
Terminal
Assembly
6 720 610 599 - 01.TD
Fig. 20 Flue with extensions
Flue
Turret
Clamp
Flue Terminal
Extension Flue Duct
Wall Sealing Gasket
6 720 610 599 - 01.TD
Fig. 21 Flue components
3.8.3
Flue duct preparation and assembly
Measure the flue length L. Refer to fig. 22, 23.
6 720 611 445 GB (03.11)
19
Installation
The assembly will be made easier if a solvent free
grease is lightly applied i.e Silicone lubricant, to the
male end of the ducts.
L
NOTE: An inner wall sealing plate is provided
which should be fitted to the ducts before assembly.
Push the assembly through the wall and fix the turret to
the appliance using the screws provided. Refer to fig.
25.
120
6 720 610 599 - 01.TD
Flue Turret
Fig. 22 Flue length - rear
Flue seal
L
Retaining
Screw
Appliance
Flue Socket
Flue Turret to
Boiler Sealing
Gasket
6 720 610 599 - 01.TD
Fig. 25 Flue turret
6 720 610 599 - 01.TD
Fig. 23 Flue length - side
Measure ‘L’ from the end of the metal section of the flue
terminal to the centre of the flue outlet on the boiler as
shown in Fig. 22 & Fig. 23 and deduct 90mm from that
measurement.
Cut both inner and outer flue pipe square at the opposite end to the terminal without creasing the tubes.
Ensure that the turret is fully entered to the socket on
the boiler.
If the terminal is within 2 m of the ground where there is
access then an approved terminal guard must be fitted.
The guard must give a clearance of at least 50 mm
around the terminal and fixed with corrosion resistant
screws.
Remove any burrs before fitting the terminal to the turret.
Outer Wall Face
Flue Terminal
Wall Sealing Gasket
6 720 610 599-00.TD
Fig. 24 Flue terminal position
Assemble flue system completely. Push the ducts fully
together and clamp in the positions. The slope of the
terminal outlet must be directed as per Fig. 24.
20
6 720 611 445 GB (03.11)
Electrical connections
4
Electrical connections
B Remove screw and slide terminal cover forwards to
remove. Refer to fig. 27.
B Always disconnect the power supply to
the appliance at the mains before carrying out any work on the electrical systems and components.
3
0
4
2
5
1
E
All control and safety systems are built into the appliance.
B Allow mains cable to protrude at least 50 cm from
wall.
B To maintain the splash-proof (IP) design: cut the
cable grommet hole size to match the diameter of the
cable, see fig. 28.
6 720 611 137 -07.1O
B The appliance must be earthed.
Fig. 27
B It must be possible to completely isolate the appliance with at least 3mm contact separation in both
poles.
B Cut cable grommet to diameter of cable.
3
0
2
The wiring between the appliance and the electrical
supply shall comply with current IEE Wiring Regulations
(and any local regulations which apply) for fixed wiring
to a stationary appliance.
4
5
1
E
• Supply: 230 V ~ 50 Hz, 150 Watts
• External fuse 3 A
• The system connected to the boiler must NOT have
a separate electrical supply
8-9
• Water Protection IPX4D (with fascia blanking plate
fitted or IP20 without blanking plate).
4.1
5-7
Connecting the appliance
To gain access to the mains connection remove the
drop down facia cover. The drop down cover is
removed by lowering it to the horizontal position and
pushing firmly upwards at the rear of the supports to
release the cover. Lift cover from the appliance.
After installation (or in the event of an electrical fault) the
electrical system shall be checked for short circuits,
fuse failure, incorrect polarity of connections, earth continuity and resistance to earth.
10-12
13-14
6 720 611 137-08.1O
Fig. 28
B Feed cable through cable grommet and connect the
mains supply cable, see fig. 29.
B Secure cable in cable grommet by means of cable
grip.
L
N NS
B Pull out cover panel at the bottom and remove. Refer
to fig. 26.
3
0
2
4
5
1
E
6 720 611 137-09.1O
Fig. 29
Fig. 26
6 720 611 445 GB (03.11)
21
Electrical connections
4.2
Wiring to your system
Mains electricity supply: The boiler should be connected to the permanent mains supply as described in
section 4.1 This also provides the electrical supply to
the system.
Y-S-Module
Note: This must be the only electrical supply to
the system. This ensures the safety of a single
fused supply.
LR LS NS PE PE DV LS NS
The boiler can only be wired to a remote system junction
box.
Note: A pump is not built into the boiler and must be fitted externally.
The diagram shows the overall wiring details. A cable is
fitted at the factory, between the boiler control panel
and the Y-S module. This module is designed to provide
the correct voltage interface.
TO BOILER AND
SYSTEM
INSIDE
OF BOILER
INSTALLATION
WIRING
OUTSIDE
OF BOILER
Other connections to
Terminal Strip according
to Proprietary instructions
Timer
Table 10
Y-S Module
Remote Junction Box
LS
L
NS
N
PE
E (Earth)
DV
Demand (Switched Live)
REMOTE PRE-WIRED
˜ JUNCTION BOX
MAINS SUPPLY
L N E
System
Water
Valve(s)
Note:
MAINS 230V
LIVE SUPPLY
Frost Stat
Upon completion of the electrical connections check for
earth continuity, correct polarisation and resistance to
earth.
N NS LS LR
L
Room Stat
If a room thermostat and/or frost thermostat is required,
these must also be connected to the junction box
according to the proprietary instructions.
HEATRONIC CONNECTOR
CONTROL
BOARD
Tank Stat
The other connector in the module must be used for wiring to the remote junction box as shown. It is the
responsibility of the installer to connect all other system
components i.e. water valve/s, pump, programmer etc.
to the proprietary junction box according to the instructions supplied with the box. Worcester Heat Systems
cannot be held responsible for any incorrect wiring to
these parts of the system.
PRE-WIRED
BOILER/PUMP
˜DEMAND
Terminal
Strip
PUMP
This must be the only electrical
supply to the Junction Box
Fig. 30 Wiring to the Y-S module
22
6 720 611 445 GB (03.11)
Commissioning
5
Commissioning
27
136 365
61
317 366 367
358
ECO
364
363
135
E
310
295
15
361
170
170
172
6 720 611 137-11.1O
Fig. 31
15
27
61
135
136
170
172
295
310
317
358
361
363
364
365
366
367
Safety valve
Automatic vent
Reset button
Master switch
Temperature control for boiler
Service cocks on boiler flow and return
Gas cock (shown in on position)
Appliance type sticker
Function control (Service only)
Multi function display
Condensate trap
Drain valve
Indicator lamp for burner
Indicator lamp for power supply
“Chimney sweep” button
Service button
No function
6 720 611 445 GB (03.11)
5.1
Commissioning
Never run the appliance when empty or
unpressurised.
i
The operational CO2 level is set at the factory and no adjustment is necessary when
installing a natural gas fired appliance.
Benchmark Water Treatment: For optimum performance after installation, this boiler and its associated central heating system should be flushed in accordance
with the guidelines given in BS 7593:1992 - Treatment
of water in domestic hot water systems. Full instructions
are supplied with proprietary cleansers sold for this purpose. If an inhibitor is to be used after flushing, it should
be used in accordance with the inhibitor manufacturers
instructions. The inhibitor must not be added until all the
cleaner has been removed.
23
Commissioning
To drain the appliance shut the system valves and open
the drain valve.
Suitable flushing agents and inhibitors are available from
Betz-Dearborn Tel: 0151-4209563 and Fernox Tel:
01799-550811. Instructions for use are supplied with
the these products.
B Before commissioning, the gas supply pressure must be checked at the gas supply pressure test point (see page 6, fig. 2, item 7).
Natural gas appliances must not be operated if
the gas supply pressure is below 18 mbar or
above 24 mbar. LPG appliances must not be
operated if the supply pressure is not 37 mbar
at the inlet to the appliance.
B Unscrew the condensation trap (358) and pull out, fill
with approx. 1/4 l of water and refit. Refer to fig. 31.
B Open all system radiator valves.
B Check the automatic air vent is open (27) see Fig. 31
B Turn on service valves (170), fill central heating system.
B Vent radiators.
B Check that the gas type specified on the identification plate matches that of the gas supply.
Switching off the appliance
B Set the master switch to (0).
The green indicator lamp goes out.
B Always disconnect the appliance from
the power supply (fuse, circuit breaker)
before carrying out any work on the
electrical systems or components.
5.3
Switching on the Boiler
The central heating flow temperature is adjustable
between 50°C and 88°C. refer to table 11, page 26.
B Turn the temperature control to set the flow temperature to a level appropriate to the type of central heating system:
– Low-temperature heating: setting “E”
(approx. 75°C)
– Central heating systems for flow temperatures up
to 88 °C: limited “max” setting for low-temperature operation (see page 26).
When the burner is alight, the red indicator lamp
lights up.
B Turn on gas cock (172). Refer to fig. 31.
B If a domestic hot water cylinder is fitted, set the hot
water cylinder thermostat to 60°C.
5.2
Switching the appliance on/off
Switching on
B Switch on the appliance at the master switch (I).
The indicator lamp shows green and the display will
show the boiler flow temperature.
6 720 611 137-12.1O
Fig. 33
5.4
System controls
B Set room thermostat to the desired room temperature.
B Set time clock and the on/off periods. Refer to the
instructions with the control.
6 720 610 333-04.1O
5.5
Fig. 32
i
If the display alternates between -II- and
the boiler flow temperature, the trap filling
programme is active.
The trap filling programme ensures that the condensation trap is filled after the appliance has been installed
or after the appliance has been out of use for a long
period or the mains supply has been interrupted. For
that reason, the appliance remains at minimum heating
output for 15 minutes.
24
B Set the thermostatic radiator valves to the desired
settings.
Frost protection
The appliance has an in-built frost protection device
which is generally suitable for most applications.
B Leave master switch switched on.
If the appliance is to be left for long periods switch the
central heating off:
B Add a suitable anti-freeze fluid to the water in the
central heating system.
Suitable products are available from Betz-Dearborn
Tel: 0151-4209563 and Fernox Tel: 01799550811.
6 720 611 445 GB (03.11)
Commissioning
5.6
i
Fault Condition
A list of faults that may occur is given on
page 40.
In the unlikely event of a fault occurring while the appliance is in operation:
The display then shows a fault code and the button
may also flash.
If the button
flashes:
B Press and hold the button
until the display shows
“– –”.
The appliance will then start up again and the display
will show the boiler flow temperature.
If the button
does not flash:
B Switch the appliance off and then on again at the
master switch.
The appliance will start up again and the boiler flow
temperature will be displayed.
6 720 611 445 GB (03.11)
25
Individual settings
6
Individual settings
6.1
Mechanical settings
6.2
Settings on the Bosch Heatronic
6.1.1
Setting the boiler flow temperature
6.2.1
Operating the Bosch Heatronic
The central heating flow temperature can be set to
between 50°C and 88°C.
The Bosch Heatronic enables easy setting and checking of a large number of appliance functions.
Limited maximum setting for low-temperature
operation
This description is limited to those functions required
for commissioning.
The temperature control is factory limited to setting E,
giving a maximum flow temperature of 75°C.
For a full description of all available functions, please
refer to the Service booklet for the Engineer, order no.
7-181-465-346.
Adjustment of the heating output to the calculated heat
demand is not required by the heating systems regulations.
2
5
1
Removing the maximum setting limit
For heating systems which require higher flow temperatures, the maximum setting limit can be removed.
B Lift off the yellow button on the temperature control
with a screwdriver.
6 720 611 137-14.1O
4
3
Fig. 35 Appliance controls
6 720 611 137-13.1O
Fig. 34
B Rotate yellow button through 180° and replace (dot
facing inwards).
The boiler flow temperature is no longer limited.
Control setting
boiler flow temperature
1
2
3
4
5
E
max
approx. 50°C
approx. 55°C
approx. 60°C
approx. 65°C
approx. 70°C
approx. 75°C
approx. 88°C
Table 11
1
2
3
4
5
Service button
“Chimney sweep” button
Temperature control for boiler flow
Function control
Display
Selecting service function:
i
Note the positions of the temperature controls
and
. After completing the settings, return the temperature controls to
their original positions.
The service functions are subdivided into two levels:
Level 1 comprises service functions up to function 4.9,
Level 2 consists of service functions from 5.0 upwards.
B To select a service function on Level 1: press and
hold the
button until the display shows – –.
B To select a service function on Level 2: press and
hold the buttons
and
simultaneously until the
display shows = =.
B Then turn the
temperature control to select the
required function.
Service function
Code no.
See page
Anti-cycle time
Max. boiler flow
temperature
Switching difference
Max. heating output
2.4
27
2.5
2.6
5.0
27
27
27
Table 12
The service function 5.0 may be reset.
26
6 720 611 445 GB (03.11)
Individual settings
Entering a setting
B To enter the setting for a function, turn the function
control.
B Press and hold the
and
buttons simultaneously until the display shows = =.
The
and
buttons will light up.
Storing a setting
B Level 1: press and hold the
play shows [ ].
button until the dis-
B Level 2: press and hold the
and
buttons simultaneously until the display shows [ ].
6 720 611 137-15.1O
After completing the settings
B Reset the temperature controls
control to their original positions.
6.2.2
and the function
Setting the anti-cycle time
(Service Function 2.4)
Fig. 36
B Turn the temperature control
until the display
shows 5.0.
After a short delay, the display then shows the set
heating output in percent.
This service function is only active if Service Function
2.7, automatic anti-cycle time, is deactivated.
The anti-cycle time can be set to between 0 and 15 minutes (is factory set to 3 minutes).
If the setting 0 is entered, the anti-cycle time is inactive.
The shortest possible anti-cycle time is 1 minute (recommended for single-pipe and hot-air heating systems).
6.2.3
Setting the maximum boiler flow temperature (Service Function 2.5)
The maximum flow temperature can be set to between
50°C and 88°C (factory setting).
6.2.4
i
Setting the switching difference
(Service Function 2.6)
If the appliance is connected to an outside
temperature controlled programmer, the
programmer sets the switching difference.
It does not need to be set on the appliance.
The switching difference is the permissible divergence
from the specified flow temperature. It can be set in
increments of 1°C. The adjustment range is 1 to 30°C
(is factory set to 0°C). Minimum flow temperature is
30°C.
6.2.5
Fig. 37
B Refer to the settings tables for heating and cylinder
charging output to obtain the relevant code for the
desired heating output in kW (see page 41).
B Turn the function control until the display shows the
desired code number.
The display and the
and
buttons will flash.
B Measure the gas flow rate and compare with the figures specified for the code number displayed. If figures do not match, adjust the code number!
B Press and hold the
and
buttons simultaneously until the display shows [ ].
The heating output is now stored.
Setting the heating output
(Service Function 5.0)
The heating output can be set to any level between min.
rated heat output and max rated heat output to limit it to
the specific heat requirements.
i
6 720 611 137-16.1O
The full rated heat output is still available
for hot water or charging the hot water cylinder even if the heating output has been
limited.
6 720 611 137-17.1O
Fig. 38
B Return the temperature controls
and
to their
original positions.
The display will revert to the boiler flow temperate.
The factory setting is the max. rated heat output.
B Set the room thermostat and thermostatic radiator
valves to max. temperature.
6 720 611 445 GB (03.11)
27
Individual settings
6.3
Setting the gas/air ratio
The appliance is set at the factory and adjustment to the
CO2 settings (gas/air ratio) is only required where the
appliance has been stripped down and assembled or if
the fan, burner or gas valve are replaced or the appliance has been converted to a different gas type, see
section .7
28
6 720 611 445 GB (03.11)
Converting the appliance to different gas types
7
Converting the appliance to different gas types
The setting is factory sealed at maximum. Adjustment to
the rated heat input and min. heat input is not necessary.
Checking the gas supply pressure
B Check the gas supply pressure at the gas supply
pressure testing point.
i
Natural gas appliances must not be operated if the gas supply pressure is below
18 mbar or above 24 mbar.
LPG appliances must not be operated if
the supply pressure is below or above
37 mbar.
Natural gas
7.1
Setting the gas/air ratio
The gas/air ratio may only be adjusted on the
basis of a CO2 measurement at max. heat output
and min. heat output using an electronic tester.
B Switch off the appliance at the master switch (O).
B Remove the outer case (see page 15, refer to
fig. 14).
B Switch on the appliance at the master switch (I).
B Set room thermostat to maximum temperature.
B Open thermostatic radiator valves.
B Unscrew sealing plug from flue gas testing
point (234). Refer to fig. 39.
B Insert testing probe about 135 mm into the flue gas
testing point and seal testing point.
• Appliances for natural gas type G20 are factory set
to Wobbe-Index 15 kWh/m3 and 20 mbar supply
pressure and sealed.
234
6 720 610 599 - 01.TD
Fig. 39
B Press and hold
button until the display shows – –.
The
button will light up.
6 720 611 137-18.1O
Fig. 40
B Turn the temperature control
until the display
shows 2.0 .
After a short delay, the current operating mode setting will be displayed (0. = Normal mode).
6 720 611 137-19.1O
Fig. 41
6 720 611 445 GB (03.11)
29
Converting the appliance to different gas types
B Turn the function control until the display shows 2. (=
max. rated heat output).
The display and the
button will flash.
B Remove the seal from the gas valve adjusting
screw (64) and adjust the CO2 level to the figure
given in Table 13 for min. rated heat output.
64
6 720 611 137-20.1O
Fig. 42
B Measure the CO2 level.
B Prise off the seal on the gas flow restrictor.
B Adjust the gas flow restrictor (63) to obtain the CO2
level given in Table 13. Refer to fig. 43.
3928-74.1R
Fig. 45
B Re check the levels at min. and max. rated heat output and re-adjust if necessary.
B Turn the temperature control
anti-clockwise as
far as the stop so that the display shows 0.
(= Normal operating mode).
The display and the
button will flash.
63
B Press and hold the
shows [ ].
button until the display
B Reset the temperature controls
and function control to their original positions.
The display will revert to the boiler flow temperature.
6 720 610 332-64.1R
Fig. 43
Gas Type
Natural gas type
G20
LPG G31
(propane)
B Remove testing probe from the flue gas testing
point (234) and refit sealing plug.
B Re-seal gas valve adjusting screw and gas flow
restrictor.
CO 2 reading
at max.
rated heat
output
CO 2 reading
at min. rated
heat output
9.2 %
8.8 %
10.8 %
10.5 %
B Replace outer case and secure.
B Set room thermostat and thermostatic radiator valves
to the desired temperature.
Table 13
B Turn the temperature control
anti-clockwise until
the display shows 1. (= min. rated heat output).
The display and the
button will flash.
6 720 611 137-21.1O
Fig. 44
B Measure the CO2 level.
30
6 720 611 445 GB (03.11)
Converting the appliance to different gas types
7.2
Testing combustion air/flue gas at set heat output
7.2.1
Testing the O 2 or CO2 level in the combustion air
i
By testing the O2 or CO2 level in the combustion air the gas tightness of a type C13
or C33 flue system can be checked. The
O2 level must not be less than 20,6 %.
The CO2 level must not exceed 0,2 %.
B Press and hold the
button until the display
shows – –.
“Chimney sweep” mode is now active.
The
button will light up and the display shows the
boiler flow temperature.
i
In “chimney sweep” mode, the appliance
switches to max. rated heat output or the
set heating output. You then have 15 minutes in which to measure the levels. After
that, the appliance switches back from
“chimney sweep” mode to normal mode.
B Remove sealing plug from combustion air testing
point (234.1, Fig. 46).
7.2.2
Testing CO and CO 2
B Press and hold the
button until the display
shows – –.
“Chimney sweep” mode is now active.
The
button will light up and the display shows the
boiler flow temperature.
i
You have 15 minutes in which to measure
the levels. After that, the appliance switches back from “chimney sweep” mode to
normal mode.
B Remove sealing plug from flue gas testing point
(234, fig. 46).
B Insert testing probe about 135 mm into the testing
point and seal testing point.
B Measure CO- and CO2 levels.
B Refit sealing plug.
B Press and hold
button until the display shows – –.
The
button will stop flashing and the display
shows the boiler flow temperature.
B Insert testing probe about 80 mm into the testing
point and seal testing point.
234.1
234
6 720 610 599 - 01.TD
Fig. 46
B Measure O2 and CO2 levels.
B Refit sealing plug.
B Press and hold
button until the display shows – –.
The
button will stop flashing and the display
shows the boiler flow temperature.
6 720 611 445 GB (03.11)
31
Maintenance
8
Maintenance
B Always disconnect the appliance from
the electrical power supply (fuse, circuit
breaker) before carrying out any work on
the electrical systems or components.
B Always turn off the gas cock before carrying out any work on components
which carry gas.
i
There is a special Service booklet for the
Engineer, order no. 7-181-465-346, available to competent persons.
i
All safety and control systems are monitored by the Bosch Heatronic. In the event
of a component fault, the display shows a
fault code.
B The User should be recommended to have the appliance serviced regularly by a competent person (see
Maintenance Contract).
B Use only genuine spare parts
B Refer to the Spare Parts List when ordering spare
parts.
B Always renew seals and O-rings removed during
servicing or repair work.
B Use only the following types of grease:
– Water valve: WRAS approved silicon based
grease
– Unions: approved sealant.
B To drain the appliance shut the system valves and
open the drain valve.
B Upon completion of any electrical work check for
earth continuity, correct polarisation and resistance
to earth.
32
6 720 611 445 GB (03.11)
Maintenance
8.1
Pre-Service Check List
Date
1
Call up the last fault stored by the
Bosch Heatronic, Service Function .0,
(see page 34).
2
Check ionisation current, Service
Function 3.3, (see page 34).
3
Perform visual check of air/flue
duct.Visual check of diaphragm for
soiling and splits (see page 36).
4
Check gas supply pressure
(see page 29).
5
Test combustion air/flue gas
(see page 31).
6
Check CO2 setting for min./
max. (gas/air ratio)
(see page 29).
mbar
min. %
max. %
7
Check gas and water systems for
leaks (see page 16).
8
Check heat exchanger
(see page 34).
9
Check burner (see page 35).
mbar
10 Clean condensation trap
(see page 35).
11 Check electrical wiring for damage.
12 Check heating programmer settings.
13 Check appliances that are part of
the heating system.
Table 14
6 720 611 445 GB (03.11)
33
Maintenance
8.2
Description of servicing operations
The combustion performance must be checked before
and after any servicing work on the combustion and
burner components. Refer to section 7.1.
B Unscrew condensation trap and place suitable container underneath. Refer to fig. 48.
B Remove the fan and the burner as described in the
text headed “Burner” (see page 35).
Check “Last fault stored”:
B Select Service Function .0 (see page 26 “Selecting
service function”).
There is a list of the fault codes in the Appendix (see
page 40).
To delete “Last fault stored”:
B Turn function control anti-clockwise as far as the
stop.
B Press and hold the
button until the display
shows [ ].
The last fault stored has now been deleted.
6 720 610 332-72.1R
Fig. 48
Checking the ionisation current,
Service Function 3.3
B Select Service Function 3.3 (see page 26 “Selecting service function”).
B Loosen any deposits in the heat exchanger from top
to bottom using the cleaning blade. Refer to fig. 49.
If the display shows 2 or 3, the ionisation current is OK.
If the display shows 0 or 1, the electrode assembly
(32.1, page 6) must be cleaned or replaced.
Primary Heat exchanger
There is a special accessory kit (no. 840) for cleaning
the heat exchanger, order no. 7 719 001 996.
B Check control pressure on the air - gas mixer unit at
max. rated heat output using an electronic manometer.
6 720 610 332-73.1R
Fig. 49
B Clean the heat exchanger from top to bottom using
the brush. Refer to fig. 50.
6 720 610 332-69.1R
Fig. 47
i
The heat exchanger should only be
cleaned if the control pressure is
4.2 mbar (R29 HE)
6.2 mbar (R40 HE)
(depression) or less.
6 720 610 332-74.1R
Fig. 50
B Flush the heat exchanger from the top.
B Remove cleaning access cover (415, page 6) and
the metal plate below it, if present. Refer to fig. 2.
34
6 720 611 445 GB (03.11)
Maintenance
B Clean out the condensate collector and trap connection (with other end of brush).
6 720 610 332-75.2R
Fig. 51
B Refit the clean-out cover using a new seal and
tighten screws to torque of approx. 5 Nm.
Burner
B Check that the gas cock is turned off and the master
switch is in the OFF position.
B Remove the clips (1.) and unscrew the two bolts (2.).
Refer to fig. 52.
B Unscrew and remove the two hexagon screws securing the fan (3.).
7 181 465 330-09.2R
Fig. 53
B Re-assemble burner in reverse order, inspect seal for
damage and replace if necessary.
B Adjust gas/air ratio. Refer to section 7.2.
B Slacken fully the rear securing bolt (4.).
Condensation trap
B Remove the burner coverplate.
In order to prevent spillage of condensate, the condensation trap should be completely removed, (see
page 34, fig. 48).
4.
B Unscrew condensation trap and check connection to
heat exchanger is clear.
B Remove condensation trap cover and clean.
2.
B Fill condensation trap with approx. 1/4 l of water and
refit.
3.
1.
Electrode assembly
B Switch off the master switch.
B Pull off the leads from the electrodes. Refer to fig. 2.
Fig. 52
B Unscrew the two fixing screws and carefully remove
the electrode assembly. Refer to fig. 47.
B Remove the burner skin and clean components. Do
not use a wire brush. Refer to fig. 53.
B Clean the electrodes with a non-metallic brush. (The
spark gap should be 4 mm ± 0.5 mm.)
7 181 465 330-04.1R
B Replace and re-connect the assembly taking care not
to mislay the inspection window.
6 720 611 445 GB (03.11)
35
Maintenance
B Refit and prime the siphon.
Diaphragm in mixer unit
Take care not to damage diaphragm
(443) when removing and refitting it.
B Open mixer unit (29).
B Carefully withdraw diaphragm (443) from fan intake
tube and check for soiling and splits.
Condensate
Drain
Siphon
3.
Drain
plug
443
29
6 720 611 137 - 23.1O
Fig. 55
Electrical wiring
1.
B Check the electrical wiring for physical damage and
replace any damaged wires.
2.
6 720 610 790-07.2R
Fig. 54
B Carefully refit diaphragm (443) the correct way round
into the fan intake tube.
i
The flaps of the diaphragm (443) must
open upwards.
B Seal the mixer unit (29).
Siphon
B Unscrew the clip and disconnect the pipe to the
siphon.
B Remove the drain plug to drain the siphon.
B Unscrew the securing nut from beneath the side
facia and remove the siphon. Refer to figure below.
36
6 720 611 445 GB (03.11)
Maintenance
8.3
B Remove the pcb control board.
Replacement of Parts
Before changing any components check that the gas is
turned off and that the appliance is electrically isolated.
When necessary close the system valves and drain the
appliance.
Refitting is a reverse of the procedure for removal using
new seals or o-rings as appropriate.
8.3.1
PCB control board and transformer
B Switch off the appliance.
B Disconnect appliance from the power supply.
B Unplug all connectors from the control box (inc.
keyed plug). Access is gained by removing the covers. Refer to fig. 26, 27.
B Remove screw holding power connector earth lead
and remove earth lead.
B Remove two top fixing screws from the control box.
Refer to fig. 56.
1
3
2 4
7 181 465 330-10.1R
3
1
4
3
2 4
2
5
Fig. 57
1
E
Fuses
1
3
2 4
B Remove the connections covers. Refer to fig. 26,
27.
6 720 611 137 - 23.1O
Fig. 56
B Lower the control box.
B Unscrew earth lead.
B Unscrew four fixing screws from cover plate. Refer to
fig. 63.
The fuses are located adjacent to the mains connector
block and connector ST18. Refer to fig. 4.
Fuse, item 312, is only replaceable by removing the
pcb.
Spare fuses are fixed to the connections cover.
A fuse pack is available: Part number 8 744 503 010 0.
B Prise off cover plate.
B Pull off transformer.
B Remove pcb holder.
6 720 611 445 GB (03.11)
37
Maintenance
8.3.2
Fan Assembly
8.3.4
3.
Gas Valve
B Check that the gas cock is turned off.
B Lower the control panel. Refer to fig. 59.
2.
1.
1.
4.
6 720 611 137- 25.1O
2.
B Pull off the solenoid connections at the rear of the
valve.
B Undo the union, within the inner casing, securing the
valve to the gas/air tube. Refer to fig. 58.
B Remove the white plastic cap from the gas valve.
B Release the gas inlet union at the manifold assembly.
B Unscrew the two screws securing the gas valve
assembly bracket to the back panel and withdraw the
assembly.
1.
7 181 465 330-05 1R
Fig. 58
B Switch off the appliance.
B Disconnect the appliance from the power supply.
B Undo lower pipe union on gas pipe (1.). Refer to
fig. 58.
B Transfer the bracket and inlet pipe assembly to the
new gas valve.
B Check for gas soundness when the new gas valve
has been fitted.
B Recheck the combustion performance as described
in section 7.1.
B Remove fan lead and earth connector (2.). The earth
connector has a positive clip fixing.
B Remove fixing screws attaching fan to the burner
cover (3.).
B Remove fan together with gas pipe and mixer unit.
B Separate the fan from the pipe and mixer unit by
twisting the mixer unit to release it (4.).
8.3.3
Sensors
B Check that the appliance is electrically isolated.
Central Heating Flow Temperature Sensor –
Item 36, fig. 2
B Pull-off the connector.
B Release the sensor clip and withdraw the sensor.
B Apply heat transfer paste to the replacement sensor.
Safety Temperature Limiter – Item 6, fig. 2
B Pull-off the connectors.
B Unscrew the sensor.
Flue Temperature Limiter – Item 9, fig. 2
B Pull-off the connectors.
B Unscrew the sensor.
38
6 720 611 445 GB (03.11)
Maintenance
B Undo the central heating flow union.
B Undo the grey plastic cap at the base of the heat
exchanger.
B Unscrew and remove the condensate trap. Refer to
section 8.2.
B Unscrew and remove the two screws securing the
heat exchanger top bracket to the rear panel.
B Lift up the flue duct, item 271, refer to fig. 2.
B Pull forward from the top and lift the heat exchanger
from the casing.
B Transfer components, as necessary, to the new heat
exchanger.
B Ensure that all the seals are in place and all of the
connections are tight before re-commissioning the
appliance.
6 720 610 602 - 04.1O
Fig. 59
8.3.5
Electrode assembly
B Refer to section 8.2.
B Use a new seal if the existing seal is damaged.
8.3.6
Pressure Relief Valve
B Drain the appliance.
B Disconnect the drain pipe from the valve. Refer to
fig. 31.
B Pull-out the clip securing the valve.
B Pull-out the valve.
B Ensure that the replacement valve is fully entered
before fitting the clip.
8.3.7
Burner
B Refer to section 8.2.
8.3.8
Primary Heat Exchanger
6 720 610 602 - 06.10
Fig. 60
B Drain the appliance.
B Check that the gas supply is turned off.
B Check that the appliance is electrically isolated.
B Remove the fan assembly complete with the gas/air
tube and mixer assembly. Refer to section 8.3.2.
B Remove the burner. Refer to section 8.2.
B Disconnect the sensors. Refer to section 8.3.3.
6 720 611 445 GB (03.11)
39
Appendix
9
Appendix
9.1
Fault Codes
More detailed fault finding procedures are described in the Service booklet for the Engineer number 7 181 465 346.
Display
code
Description
Remedy
b1
Code plug not detected.
Insert code plug correctly, test and replace if necessary.
C1
Fan speed too low.
Check fan lead and connector, and fan; replace as
necessary.
d3
Jumper 8-9 not detected.
Connector not connected, link missing, underfloor
heating limiter tripped.
E2
boiler flow NTC sensor defective
Check boiler flow NTC sensor and connecting lead.
E9
Safety temp. limiter in boiler flow has tripped.
Check system pressure, check safety temp. limiters,
check pump operation, check fuse on pcb, bleed
appliance.
EA
Flame not detected.
Is gas cock turned on? Check gas supply pressure,
power supply, igniter electrode and lead, ionisation
sensing electrode and lead, flue duct and CO2 level.
F0
Internal error.
Check electrical connector contacts, programmer
interface module ignition leads are not loose; replace
pcb if necessary.
F7
Flame detected even though appliance switched off.
Check electrode assembly, dry pcb. Flue clear?
FA
Flame detected after gas shut off.
Check gas valve and wiring to gas valve. Clean condensation trap and check electrode assembly. Flue
clear?
Fd
Reset button pressed by mistake.
Press reset button again
P1, P2, P3,
P1...
Please wait, initialisation in progress.
24 V fuse blown. Replace fuse.
Table 15
40
6 720 611 445 GB (03.11)
Appendix
9.2
Short parts list
Key
Description
Qty GC
Spare part number
1
Sensor - Flue gas temp.
1
8 729 000 144 0
2
Sensor - boiler flow temp.
1
8 714 500 087 0
3
Control board
1
8 748 300 418 0
4
Gas valve
1
8 747 003 516 0
5
Fan assembly
1
8 717 204 373 0
6
Fan washer
1
8 729 000 183 0
7
Relief valve
1
8 717 401 012 0
8
Electrode assembly
1
8 718 107 077 0
9
Electrode lead
1
8 714 401 999 0
10
Burner skin seal
1
8 711 004 168 0
11
Transformer - facia
1
8 747 201 358 0
12
Heat exchanger washer
1
8 710 103 153 0
13
Washer set Condensation Trap
1
8 710 103 154 0
14
Fuse set
1
8 744 503 010 0
15
Primary heat exchanger
1
8 715 406 615 0
Table 16
9.3
Heating/hot water output settings
(N.G)
9.4
Heating/hot water output settings
(L.P.G)
Propane
Natural gas G20
Heat
output,
kW
Heat
input,
kW
Gas vol. flow rate
(l/min at
tV/tR = 80/60°C)
Display
code
Heat output kW
Heat input kW
40
11.0
11.1
30
8.2
8.3
14.5
50
13.7
13.9
40
11.0
11.1
19.4
60
16.5
16.6
50
13.7
13.9
24.2
70
19.2
19.4
60
16.5
16.6
29.1
80
21.9
22.2
70
19.2
19.4
33.9
90
24,7
24.9
80
21.9
22.2
38.8
100
27.4
27.7
90
24,7
24.9
43.6
100
27.4
27.7
48.5
Display
code
Table 18
Table 17
6 720 611 445 GB (03.11)
41
Yes
*
Minimu m
heat input
for 15min.
No
Boiler
operates to
ma tch
system load
and
temperature
control
setting.
Ignition sequence
Ignition spark for
5 seconds.
Burner lights.
Red light ON.
Yes
Heat demand
satisfied.
Gas va lve
closes.
Red light
OFF.
No
6 720 611 445 GB (03.11)
Repeats 5 times
(N.G.) or 3 times
(L.P.G.) before
lock out
Fan runs to purge
gas from burner.
* NOTE : The sequence ensures that the condensate siphon is not empty
after long OFF periods. (More than 24 hours without a dema nd).
6 720 611 137 - 24.1O
Appendix
Fan min.
speed for
90 secs.
Boiler
unused for
long
period.*
Operational Flow diagrams
Heat
demand.
Fan speed
reduces
over 15
secs.
9.5
Temperature
control knob
ON.
Burner
stabilises at
start speed
for 5-10 secs
Central heating function
Green
light
ON.
External
External Pump ON
Fan to
start speed.
Gas va lve opens.
9.5.1
Fig. 61
42
Mains
switch
ON.
Room thermostat
and/or mains
programmer or
link ON
Over temperat ure
shut-down if water
tempera ture is 5°C
above set va lue.
Gas valve shuts.
External pump
Pump
ON.
remains ON
Burner rem ains OFF
until flow temperature
is below set value.
Appendix
6 720 611 445 GB (03.11)
43
Appendix
EXCELLENCE COMES AS STANDARD
Manufactured exclusively for British Gas by The Bosch Group
Bosch Group, Worcester Heat Systems, Cotswold Way, Warndon, Worcester WR4 9SW.
Telephone: (01905) 754624 Fax: (01905) 754619